Method, apparatus, and composition for automatically coating the human body with plural components

ABSTRACT

In a system for coating human skin, a chemical composition, such as a cosmetic or medical formulation, is uniformly coated over the entire body or selected parts of the body of the person being coated. The system includes atomization of the coating composition, containment of the atomized spray, and residual recovery which together yield a novel method for applying chemical compositions. An improved self-tanning composition is useful in conjunction with the system is also disclosed. Also disclosed is a plural component self-tanning system.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of application Ser. No.10/191,708 filed Jul. 8, 2002, now U.S. Pat. No. 6,656,455, which is acontinuation of application Ser. No. 09/677,184 filed Oct. 2, 2000, nowU.S. Pat. No. 6,416,747, which is continuation-in-part of applicationSer. No. 09/664,218 filed Sep. 18, 2000, now U.S. Pat. No. 6,251,374,which is a continuation-in-part of application Ser. No. 09/294,689 filedApr. 19, 1999, now U.S. Pat. No. 6,199,557, which is acontinuation-in-part of application Ser. No. 08/946,764 filed Oct. 8,1997, now U.S. Pat. No. 5,922,333.

CLAIM OF PRIORITY

Applicant claims priority based on provisional patent application Ser.No. 60/154,948 filed Sep. 21, 1999, and on provisional patentapplication Ser. No. 60/157,547 filed Oct. 4, 1999.

TECHNICAL FIELD

The present invention relates generally to systems for automaticallycoating the human body or selected parts thereof with predeterminedfluids. More particularly, the invention relates to an automatedself-tanning (a/k/a sunless tanning) system, and to an improvedself-tanning composition.

BACKGROUND OF THE INVENTION

The application of various fluids to all or selected parts of the humanbody has been known literally for centuries. However, despite the longstanding and widespread practice of coating the human body with variousfluids, there has never been a successful way of automatically coatingthe human body. Therefore, prior to the present invention, it has beennecessary to apply fluids to the body manually.

Manual application of fluids to the human body results in numerousdisadvantages. First, it is almost impossible to uniformly coat thehuman body with fluids using manual application techniques. This is trueeven in the case of fluids that are provided in aerosol or spray formbecause such fluids must be rubbed in after application. Second, theapplication of fluids to certain parts of the human body, for example,the back, require the availability of an assistant in order that propermanual application can be attempted.

The foregoing difficulties are particularly apparent in the case ofartificial tanning processes, hereinafter sometimes referred to asself-tanning or sunless tanning compositions and systems. Artificialtanning has been known for more than 40 years, with artificial tanningproducts appearing on the U.S. market as early as 1959. The two keytypes of tanning processes are by colorants and bronzers.

Tanning by colorants is based on the color reaction which occurs betweencomponents of the skin and the colorant. The most commonly used chemicalfor artificial tanning is dihydroxyacetone (DHA). It is widely used incommercial artificial tanning products, and is recognized as safe andeffective by the U.S. Food and Drug Administration (FDA). DHA reactssolely with the stratum corneum. It interacts with amines, peptides andfree amino acids to generate a Maillard reaction. The resulting productsare cyclic and linear polymers that have a yellow or brown color.

Two common bronzers are juglone and lawsone. Both are naphthoquinones.When applied to skin, lawsone produces an orange hue and jugloneproduces a greenish-brown tan. They are sometimes used in combinationwith DHA to modify the color or hue of the tan or to intensify thecolor.

Numerous forms of artificial tanning products are now on the market.They include:

-   -   lotions,    -   creams,    -   gels,    -   oils,    -   sprays.

These products are mixtures of a chemically-active skin colorant or abronzer with combinations of the following:

-   -   moisturizers,    -   preservatives,    -   anti-microbial,    -   thickeners,    -   solvents,    -   emulsifiers,    -   fragrances,    -   surfactants,    -   stabilizers,    -   sunscreens,    -   pH adjusters,    -   anti-caking agents,    -   ingredients to alter the color reaction.

Users of these products often experience significant problems associatedwith the current methods for applying artificial tanning formations toskin. These problems include the following.

If not properly dried, the formulation will streak or form blotches withtime. The net result is a very nonuniform tan, with light or darkstreaks or blotches.

Certain parts of the body will stain more intensely when the formulationis spread manually. This differential staining is due to enhancedabsorption of certain skin tissue and the tendency of certain tissue toretain more absorb or trap more formulation (e.g., the wrinkles in theelbows and knees and the dense tissue in the palms).

Most products designed for manual application require components such asthickeners and polymers, which often inhibit the efficacy of DHA.

Current formulations typically take about 20 minutes to dry to thetouch, and about 1 hour before not transferring from skin to textiles.

Application of artificial tanning products is additionally complicatedby the tendency of these formulations to stain materials containingamine molecules, including certain fabrics, certain types of carpet, andcertain wall coverings and paint.

In spite of all of these problems, artificial tanning is becomingincreasingly popular. It is apparent that a need exists for a superiorapplication system which solves the foregoing problems.

There is also a need for a superior applications system for many otherapplications, including but not limited to:

-   -   self-tanning formulations,    -   sunscreens,    -   suntan lotions,    -   tanning accelerators,    -   sunburn treatments,    -   insect repellants,    -   skin toners,    -   skin bleaches,    -   skin lighteners,    -   anti-microbial compositions,    -   moisturizers,    -   exfoliants,    -   nutriments or vitamins,    -   massage aids,    -   muscle relaxants,    -   skin treatment agents,    -   burn treatment agents,    -   decontamination agents,    -   cosmetics,    -   wrinkle treatments or removers.

There are specific and significant problems with the manual coating ofeach of these products. The artificial tanning application provides agood illustration of the types of problems normally encountered whenmanually coating with these products. Artificial tanning is also one ofthe most demanding applications in that uniformity of the coating iscritical to assure uniform tanning.

SUMMARY OF THE INVENTION

The present invention comprises a system for automatically coating thehuman body, including a method of and apparatus for uniformly andrapidly coating all or selected parts of the human body. The systemincludes apparatus which atomizes (also referred to as aerosolization,nebulization, mist generation, fog generation or spray generation) achemical composition and deposits it uniformly over all or selectedparts of the human body. It is not necessary for the individualreceiving the treatment nor anyone else to manually apply any of theformulation. Also, a containment system is provided which restrains andcollects residue from the application process. The system can optionallyrecycle the materials used.

There are several major advantages resulting from the use of theinvention:

-   -   Uniform application minimizes or eliminates streaking,    -   No assistant is required for applying the composition,    -   The entire skin surface receives the same exposure to the        composition, so the uniformity of the coating is greatly        enhanced over manual application,    -   The optimal formulation for atomization is very simple, and does        not require the addition of components which may inhibit the        efficacy of the applied material,    -   The application time can be as quick as a few seconds, and        complete drying can occur in just a few minutes,    -   The containment system drastically reduces the unwanted        environmental impact,    -   Multiple applications can be used to better control the amount        of material applied per unit area, and additional substances can        be applied in separate applications.

The invention may be practiced utilizing a unitary constructionincluding both a coating chamber and apparatus for coating a personsituated within the coating chamber. A door provides ingress to andegress from the coating chamber which is provided with verticallydisposed arrays of spray discharging nozzles situated at spaced apartpoints around the periphery of the chamber. A blower circulates airthrough the coating chamber to effect drying following the coatingprocedure and to aid in containment of excess spray. An air compressorsupplies liquid for coating and compressed air for spraying the coatingliquid to the nozzles situated within the coating chamber.

In accordance with another aspect of the invention, there is provided aplural component system for coating the human body. The plural componentsystem may comprise a single discharge nozzle which simultaneously orsequentially receives fluid from separate sources. Alternatively, theplural component system may comprise two or more discharge nozzles eachreceiving fluid from a separate source. Both techniques keep variouscomponents of the composition to be applied to the skin entirelyseparate until the moment of application.

The present invention further comprises an improved self-tanningcomposition. The improved self-tanning composition is particularlyadapted for use in conjunction with the method and apparatus hereof.

REFERENCES

U.S. Patent Documents

3,932,151  1/1976 Lau 55/229 4,231,289 11/1980 Dornicent 98/1155,268,166 12/1993 Barnett 424/047 

Foreign Patent Documents

WO 94/12146 June 1994 PCT Int'l Appl.

Other Publications

-   Akins, F. J. and Marlowe, E., “Non-Carcinogenicity of    Dihydroxyacetone by Skin Painting,” Journal of Environmental    Pathology and Toxicology, 5: No. 5, pp. 349-351(1984).-   Federal Register, “Color Additive Dihydroxyacetone” 38: No. 148, p.    21615, 2 August 1973.-   Futterer, E., “Theory and Practice of Artificial Tanning: Literature    and Patent Survey,” Cosmetics and Perfumes, 88: No. 8, pp. 31-33    (1973).-   Johnson, J. A. and Fusaro, R. M., “Persistence of Skin Color and    Fluorescence after Treatment with Dihydroxyacetone,” Dermatology    188: pp. 247 (1994).-   Kurz, T., “Formulating Effective Self-Tanners with DHA,” Cosmetics    and Toiletries, 109: No. 11, starting p. 55 (1994).-   Levy, S. B., “Dihydroxyacetone-Containing Sunless or Self-tanning    Lotions,” Journal of the American Academy of Dermatology, 27: No. 6,    pp. 989-993 (1992).-   “Spray Application Processes,” BINKS training brochure TD49-2R-4,    August, 1995, BINKS Manufacturing Company, Franklin, Ill.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the invention may be had by referenceto the following Detailed Description when taken in conjunction withaccompanied Drawings, wherein:

FIG. 1 is a flow chart illustrating the invention;

FIG. 2 is a diagrammatic illustration of the system for automaticallycoating the human body of the present invention comprising the minimumrequirements thereof;

FIG. 3 is an illustration similar to FIG. 2 wherein the system of thepresent invention is further provided with containment apparatus;

FIG. 4 is an illustration similar to FIG. 3 wherein the system of thepresent invention is further provided with an air ventilation apparatus;

FIG. 5 is an illustration similar to FIG. 4 wherein the system of thepresent invention is further provided with collection apparatus forresidual spray;

FIG. 6 is an illustration similar to FIG. 5 wherein the system of thepresent invention is further provided with apparatus to effect rotationof the human body being coated;

FIG. 7 is an illustration similar to FIG. 6 wherein the system of thepresent invention is further provided with multiple discharge nozzles;

FIG. 8 is an illustration similar to FIG. 5 wherein the system of thepresent invention is adapted to the coating of a selected part of thehuman body;

FIG. 9 is a front view of an apparatus useful in the practice of theinvention;

FIG. 10 is a top view of the apparatus of FIG. 9;

FIG. 11 is an illustration of one of the spray columns of the apparatusof FIG. 9;

FIG. 12 is an enlarged view illustrating the nozzle assemblies utilizedin the spray columns of the apparatus of FIG. 9;

FIG. 13 is an illustration of a first type of prior art plural componentspray discharge system;

FIG. 14 is an illustration of a second type of prior art pluralcomponent spray discharge system; and

FIG. 15 is an illustration of a modification of the apparatus of FIGS.9-12 to provide a plural component system.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the Drawings, and particularly to FIG. 1, the systemfor automatically coating the human body of the present invention maycomprise an automated coating system for numerous types of formulations,including but not limited to the application of:

-   -   self-tanning formulations,    -   sunscreens,    -   suntan lotions,    -   tanning accelerators,    -   sunburn treatments,    -   insect repellants,    -   skin toners,    -   skin bleaches,    -   skin lighteners,    -   anti-microbial compositions,    -   moisturizers,    -   exfoliants,    -   nutriments or vitamins,    -   massage aids,    -   muscle relaxants,    -   skin treatment agents,    -   burn treatment agents,    -   decontamination agents,    -   cosmetics,    -   wrinkle treatments or removers.

The first component of such a system is the chemical composition. Thesuitability of a composition for coating is strongly influenced by itsviscosity, with the preferred viscosity being close to that of water (1centipoise). Compositions with viscosities in the 1 to 10 centipoiserange generally atomize well, and viscosities in the 10 to 100 range canbe atomized, but the resulting spray is not as fine. Higher viscositiescan be atomized, and will work, but the spray is not as fine. Mostcurrently marketed compositions of the aforementioned applications canbe made suitable for atomization either as is or with appropriatedilution.

By way of example, a more detailed description of functionalcompositions for use in practice of the invention will be based onartificial tanning compositions. Six such compositions are given inCompositions 1, 2, 3, 4, 5, and 6. Individuals skilled in this art cancreate other compositions.

Ingredient % COMPOSITION 1 Dihydroxyacetone 3.0 Water 97.0 COMPOSITION 2Dihydroxyacetone 3.0 Denatured Ethanol 20.0 Water 77.0 COMPOSITION 3Dihydroxyacetone 12.0 Denatured Ethanol 20.0 Water 68.0 COMPOSITION 4Dihydroxyacetone 10.0 Commercial Sunless- 15.0 Tanning Lotion Water 75.0COMPOSITION 5 Dihydroxyacetone 9.0 Commercial moisturizer 20.0 Citricacid 0.3 Commercial bath product 0.6 Bronzer 6.0 Water 64.1

By way of example, a suitable commercial moisturizer would includeVaseline Brand Intensive Care Aloe and Naturals lotion(Chesebrough-Ponds, Greenwich, Conn.), and a suitable commercial bathproduct would include Vaseline Brand Intensive Care Foaming Creme Bath(Chesebrough-Ponds, Greenwich, Conn.). The bronzer is a combination ofFD&C dyes that yield a golden brown color.

COMPOSITION 6 Ingredient % Bronzer 8.0 Commercial moisturizer 20.0Commercial bath product 0.6 Ethoxydiglycol 2.0 Water 69.4

By way of example, a suitable commercial moisturizer would includeVaseline Brand Intensive Care Aloe and Naturals lotion(Chesebrough-Ponds, Greenwich, Conn.), and a suitable commercial bathproduct would include Vaseline Brand Intensive Care Foaming Creme Bath(Chesebrough-Ponds, Greenwich, Conn.). The bronzer is a combination ofFD&C dyes that yield a golden brown color.

Foaming Creme Bath (Chesebrough-Ponds, Greenwich, Conn.). The bronzer isa combination of FD&C dyes that yield a golden brown color.

By way of example, suitable commercial sunless tanning preparationsinclude Coppertone® Oil-Free Sunless Tanner (Schering-Plough, Memphis,Tenn.), Neutrogena® Glow Sunless Tanning Lotion for Face and Body(Neutrogena, Los Angeles, Calif.), and Kroger® Sunless Tanning Cream(Kroger, Cincinnati, Ohio).

Compositions 1, 2 and 3 are greatly simplified versions of theformulations now on the market or reported in the past. Thissimplification is possible due to the use of the present invention forapplying compositions to skin. These simplified compositions haveseveral advantages over more complex formulations, including:

-   -   faster drying,    -   less potential inhibition of DHA efficacy,    -   less potential for irritation from chemical components (because        there are fewer components),    -   less residue on the skin,    -   less expensive,    -   more environmentally friendly.

Compositions 4 and 5 illustrate how a commercial formulation notparticularly well suited for atomization can be diluted, effectivelyatomized and uniformly coated on human skin. Similar dilutions ofproducts representing the other aforementioned applications can beeffectively atomized and coated on human skin.

There is no pH adjustment required for these compositions, although thepH can be adjusted to alter the hue of the resulting tan and to alterthe dihydroxyacetone stability.

The optimal tanning occurs with DHA at a pH of below 6.0, preferablywith the solution at a pH 3.0 to 4.0. Unbuffered DHA has a pH of about5.5. The pH on the surface of human skin is also about 5.5. Nonetheless,these formulations can be used over a wide pH range, and buffers or pHadjusters can be added.

A preferred colorant is DHA. DHA is available from Rona (Hawthorne,N.Y.).

It is effective, safe, and approved by the FDA for this application. Thepreferred DHA concentration is 0.5% to 20%, with a more preferred rangeof 3% to 15%, and a most preferred range of 5% to 12%.

Numerous other colorants can also be used. Those agents include, but arenot limited to:

-   -   crotonaldehyde    -   pyruvaldehyde    -   glycolaldehyde    -   glutaraldehyde    -   otho-phthaldehyde    -   sorbose    -   fructose    -   erythrulose    -   methylvinylketone    -   food coloring

Various dyes and UV blocking agents can be covalently linked to thecolorant or can be mixed into the composition with the colorant.

Bronzers can also be used in combination with or as an alternative toDHA. Bronzers which can be used include, but are not limited to, lawsoneand juglone. Combinations of DHA and bronzers can also be used, and canbe used to modify the resulting color (hue) and intensity of the tan.The preferred range for lawsone, juglone, and FD&C dyes is 0.5% to 10.0%with the more preferred range of 1.0% to 5.0%.

Composition 6 is an example of a formulation containing only bronzers(no DHA). The preferred range of FD&C dyes in commercially formulatedliquid form (e.g., food coloring by Adams Extract Co., Austin, Tex.) is1 to 50%, with a more preferred range of 4 to 12%. Ethoxydiglycol isadded to enhance the penetration of the dyes into the skin, to reducetransfer to clothing, and to assist in the stabilization of theformulation. The preferred ethoxydiglycol range is 1 to 20%, with a morepreferred range of 2 to 10%.

Alcohol can be added to the composition to accelerate the rate ofdrying. Denatured ethanol (USP grade, commodity chemical) works well inthis capacity. The preferred range for alcohol concentration is from1.0% to 50.0%, with a more preferred range from 10.0% to 30.0%, and amost preferred concentration of 20.0%.

Other potential additives include:

-   -   moisturizers,    -   preservatives,    -   anti-microbials,    -   thickeners,    -   solvents,    -   emulsifiers,    -   fragrances,    -   stabilizers,    -   sunscreens,    -   surfactants,    -   pH adjusters,    -   anti-caking agents,    -   ingredients to alter the color reaction.

It typically requires about 100 ml of a 5.0% DHA composition to obtain amedium to dark tan over an entire adult body (about 2 square meters ofskin). A single application of about 250 ml of a 9% dihydroxyacetonecomposition over an entire adult human body will result in a very darktan. The exact amount of dihydroxyacetone required depends will resultin a very dark tan. The exact amount of dihydroxyacetone requireddepends on the skin type and intensity of tan desired. The tan can lastfor about 2 to 7 days, but usually lasts for 3 to 4 days. Multipleapplications will darken the tan.

The second component of the invention is the atomization of thecomposition. The required atomization can be obtained by a host of ways,most of which involve passing the composition through an orifice underpressure. Methods now used to atomize solutions include the use of thefollowing systems:

• air atomization siphon feed gravity feed pressure feed internalatomization external atomization low pressure low volume high volume lowpressure • airless atomization pressurized through small orificesair-assisted air-assisted heated electrostatic using charged particlesheated charged particles high speed rotational atomizers • ultrasonic

These forms of atomization are the basis for most methods of producingatomized sprays, including misting and nebulization.

Using a single airless sprayer with a tip orifice of 0.6 mm, with acircular spray pattern of 12 inches at 12 inches from the tip, and witha flow rate of approximately 400 ml/min. the entire body (excluding thebottom of the feet) of an average-sized person can be coated withsolution in 5 to 15 seconds. In practice, the underside of the feetusually gets slightly tanned also from exposure to small quantities ofresidual artificial tanning composition on the floor of the applicationarea. The use of a single airless sprayer to apply a composition tohuman skin is illustrated in FIG. 2. In this figure and subsequentfigures, 11 designates the orifice for atomization of the composition,12 designates the atomized spray, and 13 designates the subject beingsprayed. In this configuration, an operator must direct the flow of thespray. The configuration illustrated in FIG. 2 would also work for anyof the other atomization methods aforementioned, and for any of theapplications aforementioned. The preferred atomization method is thepressure-free air-atomization system, with an internal or externalatomization configuration.

For a person to be coated as illustrated in FIG. 2 with an artificialtanning composition (or any composition of the applicationsaforementioned), several precautions should be taken. First, the personshould hold their breath during the application and during the timerequired for the spray to clear. If this process is done in an openarea, the coating should take about 5 to 15 seconds and the clearing ofresidues should take 1 to 10 seconds. Thus, the person would need tohold their breath for 6 to 25 seconds. Alternatively, they could wear afilter over their mouth, have a filter inside of their mouth, or use abreathing tube. They can also wear nose plugs or filters. Second, theeyes should be protected even though most of these formulations are notlikely to injure the eye. The simplest and most effective protection isto keep the eyes closed. Goggles or patches also work well, althoughthey leave uncoated areas that must be subsequently coated manually.Next, precautions need to be taken if one wants to avoid the exposure ofscalp hair. Scalp hair can be protected with a shower cap or any othersimilar protective covering impervious to the coating compositions.Also, hair can be coated with a water insoluble material such aspetroleum jelly. Similar protection can be used to protect hair on anyother parts of the body. Next, if atomization is from a single source,it is recommended that the person being coated turn while being coated,or that the coating apparatus be moved around the person being coated,or there be a combination of these movements. Finally, care must betaken that the nozzle remain at least several inches from the personbeing coated to prevent any possible injection of composition into theperson. Generally, spray injection occurs at pressures greater than 500psi with the person actually contacting the atomization orifice. Thepressures here are less than 80 psi, and more typically 10 to 40 psi,and the person being coated should be a foot or more from the orifice.

The issue of what to wear during coating is usually of great concern tothe person being coated. In the case of coating with artificial tanningsolution, the selection of what to wear is a matter of preference forthe person being coated. The subject can be coated nude, with underwear,with a bikini or a bathing suit, or with some form of pasties coveringtheir private parts.

The third component of the invention is containment of the spray.Containment is illustrated in FIG. 3. In this figure and subsequentfigures, 14 and 15 designate side panels and 16 and 17 designate the topand bottom panels, respectively. This type of containment is similar tothe containment of spray paint using paint booths in automobilerefinishing. Alternatively, spray containment can be obtained usingelectrostatic forces, where the atomized spray is charged and theresidual charged spray is removed by activating charged collectionplates. Of course, precautions must be taken so that the person beingsprayed and the operator are isolated from the charged plates.

Containment of the spray is very important for several reasons. Thesereasons include but are not limited to:

-   -   reducing waste,    -   avoiding spray getting onto and staining items in the immediate        surroundings,    -   facilitating capture and recovery processes,    -   better control of air flow,    -   better control of temperature and humidity.

This type of containment facilitates the use of this invention inenclosed areas such as stores or medical facilities.

Control of air and spray flow is very important to the quality of theskin coating. It is highly preferable to have an exhaust fan drawing thespray towards the person being coated, and the residual composition outof the booth. In FIG. 4 is shown the addition of an exhaust fan 18. Thefan offers several significant advantages to the invention. Theseadvantages include but are not limited to:

-   -   better control of air flow    -   shorter exposure to residue spray, requiring less time to hold        breath or breathe through filter or air line    -   faster drying of the coated composition on skin    -   better quality coating

The fan 18 should have a flow of 10 to 5000 cubic feet per minute persquare foot of opening, preferably 50 to 1000 cubic feet per minute persquare foot, and most preferably 100 to 400 cubic feet per minute persquare foot. At flow rates of below 100 cubic feet per minute per squarefoot, the air movement is sufficient to guide the cubic feet per minuteper square foot, the air movement is sufficient to guide the atomizedspray through the containment area. At flow rates of 100 to 400 cubicfeet per minute per square foot, the atomized spray is being activelydrawn through the containment area and the application and dryingprocess is enhanced. At rates above 400 cubic feet per minute per squarefoot, the atomized spray is being accelerated and the exhaust flow playsa much more prominent role in the application process. The flow rate ofthe air through the containment area is therefore a major parameterwhich can be varied to modify the characteristics of the coating of theartificial tanning composition to the skin. The drying time for thecomposition deposited on skin is also affected by flow rate, with dryingtime decreasing as flow rates increase. At rates above 100 cubic feetper minute per square foot, the drying time (to the point of no transferto other surfaces upon contact) is less than 5 minutes.

At any flow rate above 10 cubic feet per minute per square foot, theresidual atomized spray is completely removed from the containment areawithin one second. This rapid removal is important to minimize the timethe person being tanned is exposed to spray and has the potential toinhale this spray. In the absence of this air flow, the residual spraylingers in the area for several minutes, and traces can be detectedhours later. This vigorous flow also protects any individuals oroperators near the atomizing orifices from back spray.

The final element of this invention is recovery, or filtering, ofresidual composition.

This feature greatly enhances the utility of the invention because itallows the system to be self-contained in an indoor environment andpromotes a more environmentally friendly process. Without a recoverysystem, there is a potential for the exhausted residue to stain anythingit contacts. Also, there could be an accumulation of residue with time.One configuration of the recovery system is shown in FIG. 5. In thisfigure and subsequent figures, the recovery system or filter is denotedas 19. Recovery of both particulates and solvents is possible. Potentialfilters include a high-efficiency filter such as Binks' (Franklin Park,Ill.) Paint Pockets or Columbus Industries' (Ashville, Ohio)High-Capacity Supra Mini-Mesh, a form of a carbon filter, a water-washfilter, or an exchange-type resin. The efficiency of particulate andsolvent removal should be greater than 99%. As an alternative tohigh-efficiency filtering, the spray residuals could be vented to theoutside environment.

Additional features adding to the utility of the invention are shown inFIG. 6 and FIG. 7. In FIG. 6 there is shown the addition of a motorizedturntable 20. This turntable 20 will rotate the person being coated,eliminating rotation by the individual as a possible source of error orproblems. It also is a major convenience for the person being coated.The preferred rate of rotation is in the range of 1 to 60 rpm, with amore preferred range of 5 to 20 rpm, with a most preferred rate ofrotation of 12 rpm.

In FIG. 7 there is shown the use of multiple atomizing orifices. The useof multiple orifices facilitates the automation of this process, andreduces operator effort and potential error. It also reduces the timerequired to fully coat an individual. The typical round spray pattern isabout 12 inches wide at 8 to 12 inches from the orifices, so a preferredspacing of multiple orifices will be 8 to 12 inches apart, but could bepositioned from 1 to 48 inches apart. Fan patterns from wide-anglenozzles at 18 inches are typically 24 inches long and 9 inches wide.Using the preferred configuration, an individual can be coated in 5seconds or less. In FIG. 7, the orifices are aligned in a verticalpattern. The coverage of more area at one time could also be obtained byrapidly moving one or more orifices along a track or by rapidly alteringthe angle of the orifice. Other patterns are possible, includingcombinations of vertical and horizontally aligned orifices. Orificescould also be aligned radially, with the subject being sprayed withorifices aligned from 0 to 360°. Another alignment is a horizontal ringcontaining orifices that surround the body. By vertically raising andlowering the horizontal ring, the entire body or selected parts of thebody could be coated.

In an open environment, such as a beach or a park, a modified version ofconfiguration illustrated in FIG. 7 could be used to rapidly coat anindividual. It would even be possible to have a walk-through coatingsystem. An atomized spray could be produced from multiple nozzlesarranged in a single line (as shown in FIG. 7), in two single linesfacing one another and about 36 to about 48 inches apart, or multiplelines of nozzles. The preferred configuration is multiple lines, with 4lines being adequate. The atomized spray results in an area of intenseatomized solution, which would coat an individual standing in that area.The residual spray would then be dissipated into the surroundingenvironment. A fan could be used to accelerate the removal of theresiduals from the coating area.

FIG. 8 illustrates how the system of the present invention can be usedto tan a selected part of the body. In this case, just the face is beingtanned. In this figure the bottom panel of the apparatus 22 contains anopening through which one can insert his or her head. The top panel 23is arched. The high-efficiency filter is 19. The fan and back panel is18. Alternately, the setup as shown in FIGS. 2-7 could be used to tanonly a select part of the body by protecting the area not desired to betanned with appropriate barrier apparel or by screens between theatomized spray and the regions of the skin not to be coated. The barrierapparel could be any material impervious to the atomized coatingcomposition. For example, materials appropriate for use with theaforementioned coating compositions include vinyl, polyurethane, andlatex rubber. The screens can be sheets composed of any materialimpervious to the atomized artificial tanning compositions, includingmost metals or plastics. A preferred screening material is foam with animpervious aluminum foil backing. The foam is aligned with the backingaway from the atomizing orifice. The foam is preferred because itabsorbs much of the atomized spray, reducing back deflection.

FIGS. 9, 10, 11, and 12 illustrate an apparatus which may be utilized inthe practice of the invention. The apparatus 30 comprises a unitaryconstruction which includes both a coating chamber 32 adapted to receivea person to be coated with a includes both a coating chamber 32 adaptedto receive a person to be coated with a predetermined substance andvarious components utilized to effect spraying of the predeterminedsubstance onto the person situated within the coating chamber 32.

The coating chamber 32 includes a door 34 which affords ingress to andegress from the coating chamber. The coating chamber 32 is furtherprovided with a plurality of spray columns 36. As is best shown in FIG.10, the spray columns 36 are located at spaced apart points around theperiphery of the chamber 32. Those skilled in the art will appreciatethe fact that neither the number nor the precise location of the spraycolumns 36 is critical to the practice of the invention, and that otherspray column arrangements may be utilized in the practice of theinvention, if desired.

The spray columns 36 are preferably supported for pivotal movementthrough predetermined arcs under the action of a pneumatic cylinder 38.In this manner the predetermined material is discharged from the spraycolumns 36 in such a way as to assure uniform coating of thepredetermined material on a person situated within the coating chamber32. The pneumatic cylinder 38 is connected to the pivoting mechanism ofeach of the spray columns 36 through a plurality of links 40.

Referring again to FIG. 9, there is further included a blower 46 whichdirects a flow of air upwardly along an air guide 48 and then laterallyalong a top panel 50 into engagement with a plurality of baffles 52. Thebaffles 52 direct the air from the blower 46 downwardly through thecoating chamber 32, whereby the flowing air effects drying of thesprayed material and aids in recovery of the sprayed material for reuse.From the coating chamber 32 the air is directed through a plurality offilters 54 and is returned to the blower 46.

The predetermined material which is to be coated onto a person situatedwithin the coating chamber 32 is preferably provided in the form of aliquid which is received in a reservoir 60. The interior of thereservoir 60 is pressurized by compressed air which is received from anair compressor 62 through an air tank 64. Compressed air from the aircompressor 62 in the tank 64 is also directed to an air tank 66 and to amanifold 68. The air tank 66 provides compressed air for operating thepneumatic cylinder (FIG. 10). The manifold 68 directs compressed air tothe spray columns 36.

Ideally, all of the liquid from the reservoir 60 which is dischargedfrom the spray columns 36 would be received on the body of the personwithin the coating chamber 32. In actual practice, it is not possible toobtain 100% efficiency in the coating procedure. Excess liquid which isdischarged from the spray columns moves downwardly under the action ofgravity onto a drain ramp 72. A drain pump 74 receives the excess liquidthrough a suction pipe 76 and delivers it to an appropriate drain.

Referring to FIGS. 11 and 12, each spray column 36 includes an innertubular passageway 84 which receives liquid from the reservoir 60 underthe action of compressed air supplied by the air compressor 62 throughthe tank 64 and an outer tubular passageway 86 which receives compressedair from the manifold 68. Each spray column 36 is provided with aplurality of nozzles 88. Each nozzle 88 receives compressed air from theouter tubular passageway 86 through a quick disconnect 90 and receivesliquid from the inner tubular passageway 84 through a quick disconnect92. A check valve 94 prevents reverse flow of liquid back through thequick disconnect 92.

Features Contributing Significantly to the Successful Operation of anAutomated Coating System for the Human Body Incorporating the Invention

Formula:

The following formula is a combination of water, dihydroxyacetone,bronzer, moisturizer, surfactant, and penetration enhancer. The formulais:

Range Preferred water base 16%-65%  41.7% dihydroxyacetone self-tanning3%-15% 10.0% bronzer* cosmetic colorant 0%-10% 8.0% ethoxy diglycolpenetration enhancer 0%-10% 5.0% commercial film former, viscosity10%-25%  15.0% moisturizer lotion** commercial bath surfactant 0%-2% 0.6% product*** citric acid pH adjustment 0.1%-1.0%  0.2% 10x aloe veramoisturizer, tan 1%-5%  2.5% concentrate enhancer isopropyl alcohol withsolvent, 5%-25% 15.0% methyl salicylate penetration enhancer Trivosol ®emulsifier .5%-10%  2.0% *By way of example, a suitable bronzer would bea combination of the following food dyes provided by Adams ExtractCompany, Austin, Texas: 4 parts red, 2 parts yellow, 1 part green, and 3parts purple. **By way of example, a suitable commercial moisturizerlotion includes Vaseline Intensive Care Lotion (Aloe Vera Triple ActionFormula, Chesebrough-Ponds, Greenwich, CT). ***By way of example, asuitable commercial bath product includes Vaseline Intensive CareFoaming Creme Bath (Chesebrough-Ponds, Greenwich, CT).Foot Shields:

The feet are one of the most difficult parts of the body to coatuniformly. This difficulty is due in large part to the irregularstructure of feet. Also, the downward motion of the atomized mist, bothby gravity and from air currents, tends to cause the mist to settle onthe tops of the feet. Therefore, the feet are provided with shields toassure a more uniform coating of the feet. The shields may take the formof a large, bottomless shoe. The shields produce a silhouette effectfrom the top of the feet to the toes. Holes and openings are provided inthe shields which are located 0.25 to 2 inches from the feet, allowingthe mist to result in a silhouette effect rather than defined lines.

Air Shield to Deflect Air Away from the Feet:

To reduce the amount of mist settling on the feet, a plastic shieldshaped like a figure eight is placed between the fleximat flooring theuser stands on and the metal grating supporting the fleximat. Dimensionsof the figure eight are two 18 inch diameter overlapping circles with atotal width of 26 inches. The total width can vary from 18 inches to 36inches, and the circle diameters can vary from 12 inches to 20 inches.

Toweling Buffing after Coating:

After coating it is advantageous to use a towel rub to buff over theentire body to yield a more uniform coating and to remove any areas ofexcess. The toweling yields a more cosmetically pleasing result andreduces transfer to clothing. It is preferred to towel using long, lightstrokes. A cotton bath towel 16 inches by 32 inches may be used. Thetowel could vary from a hand cloth (8″×8″) to a large beach towel(18″×48″). Care must be taken not to rub so hard or too much as to ruboff the coating (or tan). Basically, the weight of the preferred towelis adequate, without additional pressure.

Stance During Coating:

The stance used during the coating is important. After trial andevaluation of numerous methods, it has been discovered that the“ballerina stance” seems to work best. Key elements of the stance are:

-   -   hands over the head        -   preferred 2 inches        -   lower limit—hands touching head        -   upper limit—arms extended fully up    -   hands parallel to the floor        -   hands could be, but not recommended to be, perpendicular to            floor in a praying stance, or facing downwardly    -   feet separated about 12 inches    -   feet separated about 12 inches        -   to allow mist to coat inside of legs        -   feet are flat on flooring        -   use of feet shields as described above            Hair Net:

Although the above-described self-tanning solution does not turn hairorange, it may accumulate on hair. To avoid this accumulation, the usercan wear a hair net or bouffant. Preferred compositions for the hair netinclude a cloth or plastic mesh or a continuous plastic sheet.

Barrier Cream:

It has been discovered that the commercial barrier cream produced byGoJo blocks the tanning solution from the skin. During the coatingprocess, this lotion can be used to prevent tanning of specific areas,such as the palms of the hands.

High Efficiency Filter:

The use of high efficiency filters to remove excess mist is important.Preferably, a Binks high-efficiency paint-pockets filter is used.

Recharging of Filter:

It has been discovered that the tanning solution trapped in the filtercan be removed with a water rinse. The solution, which is water soluble,is flushed out using water that is back-washed (water applied to the topsurface opposite of the surface facing the solution) or water,preferably under moderate (greater than 60 psi) pressure, that is hosedon the filtered surface.

Uniform Air Flow:

Uniformity of air flow is very important to assure that the mistcontinues to be applied uniformly over the body even after thepressurized spray stops. Air flow parameters are, in the downwardmotion:

most preferred 100 cfm next preferred 50 cfm to 200 cfm next preferred25 cfm to 300 cfmWarming of Air:

Atomization of liquids as done here by the nozzles results in asignificant reduction in liquid temperature (as much as 20° F.). To keepthe temperature to a warm, pleasant experience, four halogen lamps (250watts each) can be added to the system to provide both illumination andheat. A coating chamber temperature of 80° F. to 110° F. is preferred,with 90° F. to 100° F. being more preferred. Other heating devicesinclude infrared lamps and electrical heating elements.

EXAMPLES Example 1

A twenty year old female of type III skin tanned by this process. Shefirst applied a heart shaped sticker on her right arm. She covered herhair with a nylon mesh hair net and applied barrier cream over the palmsof her hands. She tanned in the coating chamber. The subject above wascoated for 7 seconds. About 300 grams of solution was applied duringsuch time. There was a subsequent 7 second period in which the mist wascirculated in the booth. The residual mist was removed from the boothand the subject dried for about 45 seconds. The subject then removed anyexcess lotion with a towel. The final result was that the subject was 1to 2 shades darker after tanning. This difference was especiallyapparent when comparing the area under the sticker with the area with nosticker. The initial color was mainly from the bronzer, and is a deepbrown color. Color was much more intense the next day, when the colorwas at least two shades darker than before tanning. After the subjectshowered, the intensity was dropped to about 1 shade darker than priorto tanning. This color, which was mainly from the dihydroxyacetone, wasgolden-brown. The color persisted about 1 shade darker for 3-4 days, andnoticeable color was present for 7 days.

Example 2

A forty-seven year old male with type II skin tanned by this process. Hefirst applied a heart shaped sticker on his right arm. He covered hishair with a nylon mesh hair net and applied barrier cream over the palmsof his hands and the bottoms of his feet. He tanned in the coatingchamber. The subject above was coated for 7 seconds. About 300 grams ofsolution was applied during time. There was a subsequent 7 second periodin which the mist was circulated in the booth. The residual mist wasremoved from the booth and the subject dried for about 45 seconds. Thesubject then removed any excess lotion with a towel. The final resultwas that the subject was about 1 shade darker after tanning. Thisdifference was especially apparent when comparing the area under thesticker with the area with no sticker. The initial color was mainly fromthe with the area with no sticker. The initial color was mainly from thebronzer, and is a deep brown color. Color was much more intense the nextday, when the color was one to two shades darker than before tanning.After the subject showered, the intensity was dropped to about 1 shadedarker than prior to tanning. This color, which was mainly from thedihydroxyacetone, was golden-brown. The subject repeated the tanningprocess again later the second day. This time, the initial tan from thecombination of previous tan and new bronzer was about 2 shades darkerthan before. Even after showering the next day, the tan was about twoshades darker than prior to initially tanning. The color persisted about2 shades darker for 3-4 days, and noticeable color was present for 10days.

Example 3

A 24 year old female with type II skin tanned as described in examples 1and 2 for five consecutive days. The results were a highly uniform, verydark tan. Her skin color was about 3 shades darker by the end of theweek. The color was golden-brown. The color remained 2 to 3 shadesdarker for about 4 days, and some color (about 1 shade) was observedafter 7 days.

Discoveries

Very Fast Drying:

Traditional sunless tanning products require 20 minutes or more to dry.The sunless tanning composition of the present invention drys within aminute after use.

Less Transfer to Clothing than Expected:

Traditional sunless tanning products do not contain bronzers becausebronzers transfer to clothing and other fabrics. The present inventionexhibits almost no such transfer.

Tan Hue Less Orange than Expected:

The combination of bronzers, tan enhancers, and a super applicationprocess produces a long lasting, golden-brown color.

Hair is not Turned Orange:

Self-tanning lotions have been reported to turn body hair orange. Theformulation and application of the present invention do not cause thehair to turn orange. First, the formulation does not penetrate the hair,but rather beads up on it. Next, it is applied in a very thin coat. Thenet result is that the hair does not turn orange.

Produces a Very Uniform Tan:

The present invention facilitates the application of a thin, uniformfilm over the entire body. Consequently, the resulting coating and tanis far superior to manual application methods.

Bronzer tends to last Longer than Expected:

The bronzer provides immediate color and a method for observing theuniformity of the tan. The uniformity of the bronzer application isgreatly enhanced because it is applied in a uniform, thin film and itssubstantivity is enhanced because of deeper penetration into skin withthe presence of a penetration enhancer.

Use of Ethoxy Diglycol as a Penetration Enhancer makes the Tan lastLonger and more Uniform:

With the use of ethoxy diglycol, the duration of uniform intense tan hasincreased from an average of about 2 days to an average of about 4 days,and some color persists for up to 14 days.

The foregoing improved self-tanning composition is advantageouslyutilized in conjunction with the method and apparatus of the presentinvention.

Plural Component Systems

As is well known by those skilled in the art, the vast majority ofcosmetics are single component systems. Examples include traditionalcreams, lotions, or sprays.

Plural component systems are a rare exception. Although many of cosmeticproducts would perform better as plural component systems, the consumermarket generally does not like or cannot deal with multiple componentsystems. Even professionals, such as beauticians, generally prefersingle component systems.

Even medical or industrial products are generally single component.Again, the end users do not like dealing with multiple componentsystems.

In some cases, these objections are circumvented by unique deliverysystems with which automatically mix the components. One example of sucha system is the dual syringe delivery apparatus used with two part epoxysystems. Another example comprises spray devices for applying paints andcoatings using plural nozzle heads.

Referring to FIG. 13, there is shown a plural component spraying system100 of the type conventionally utilized in applying paints and coatings.The spray system 100 includes a spray gun 102 having a single nozzle104. The spray gun 102 receives compressed air through a line 106. Afirst component of a composition to be applied is received through aline 108 and a second component of the composition as is receivedthrough a line 110. The two components are mixed in the nozzle 104 anddischarged therefrom as a unitary composition.

Referring to FIG. 14, there is shown a plural component spraying system120 of the type conventionally utilized in the application of paints andcoatings. The plural component spraying system 120 includes a spray gun122 having a dual discharge nozzles 124 and 126. A first component of acomposition to be applied is received by the nozzle 124 through a line128. A second component of the composition to be applied is received bythe nozzle 126 through a line 130. Compressed air is directed to thespray gun 122 through a line 132.

In the operation of the plural component spraying system 120, thecomponent parts of the composition to be applied are not mixed in thenozzles 124 and 126. Rather, the nozzles 124 and 126 each discharge aseparate and distinct component of the ultimate composition to beapplied. Mixing of the two components to form the ultimate compositionoccurs as the components which are discharged from the nozzles 124 and126 simultaneously engage the surface to be coated.

FIG. 15 illustrates an adaptation of the apparatus illustrated in FIGS.9, 10, 11, and 12 and described hereinabove in connection therewithwhereby the apparatus is adapted for plural component spraying.

A nozzle 140 receives fluid from two passageways 142 and 144. Remotelyoperated valves 146 and 148 are utilized to control the flow of fluidfrom the passageways 142 and 144, respectively, to the nozzle 140.

The fluids received by the nozzle 140 from the passageways 142 and 144through the remotely operated valves 146 and 148, respectively, maycomprise the components of a plural component system to be applied, forexample, to the human body. Alternatively, the passageways 142 and 144may be utilized to supply entirely separate fluids which are appliedsequentially. For example, a skin preconditioner could be suppliedthrough the passageway 142 and discharged from the nozzle 140 forapplication to the skin of the person to be tanned, allowed to remain incontact with the skin of the person to be tanned for a predeterminedperiod of time, and thereafter removed from the skin by towel rubbingprior to the application of a self-tanning composition which is receivedby the nozzle 140 through the passageway 144 and discharged by thenozzle onto the skin of the person to be tanned.

Those skilled in the art will appreciate the fact that the apparatusillustrated in FIG. 15 is not limited to receiving the discharging twofluids. Rather, multiple lines can be connected to the nozzle throughmultiple remotely operated or valve components thereby facilitating theapplication of a plurality of fluids either simultaneously orsequentially. The remotely operated valves are conventional inconstruction and operation and may operate responsive to electrical,electromagnetic, pneumatic, and/or hydraulic signals.

The plural component spraying systems shown in FIGS. 13, 14, and 15 canbe used with a wide variety of nozzles, all of which are listed in U.S.Pat. No. 5,922,333 which is assigned to the assignee hereof. Includedare traditional atomization nozzles and electrostatic nozzles.

The plural component spraying systems of FIGS. 13, 14, and 15 areadvantageously used to apply self-tanning (a.k.a. sunless tanning)compositions. For example, a DHA/bronzer/moisturizer mixture maycomprise a first component and a tan enhancing component, which normallywould destabilize the DHA component, and may comprise the secondcomponent of a plural component self-tanning composition. Examples ofthe tan enhancing component include penetration enhancers and materialswhich effect the chemical binding of the DHA to skin components. Bysimultaneously or sequentially misting the two components, an enhancedtan is achieved without requiring the consumer to deal with amulti-component system.

In a second example, a plural component wrinkle treatment which includessolutions at different pHs, or which rapidly react with each other, isapplied to the skin sequentially.

Yet another example comprises on-skin polymerization. This is used tospray apply a body barrier layer which is impervious to water,radiation, etc. In this example, the solutions which contain reactiveingredients come into contact only after being applied to the skin.

Still another example is the use of an activator and base. The twocomponent hydrogen peroxide system which is disclosed in U.S. Pat. No.6,117,118 is advantageously applied by a plural mist-on processillustrated in FIGS. 13, 14, and 15 and described hereinabove inconjunction therewith. The end effect is whole-body bleaching of asunless tan.

Although preferred embodiments of the invention are illustrated in thedrawings and described in the detailed description, it will beunderstood that the invention is not limited to the embodimentsdisclosed, but is capable of numerous modifications and rearrangementsof parts and elements without departing from the spirit of theinvention.

1. A plural component process for coating the human body comprising thesteps of: providing a first component of a human body coatingcomposition; providing a second component of the human body coatingcomposition including an agent which would adversely effect the firstcomponent if mixed herewith; maintaining the first and second componentsof the human body coating composition separate from one another prior toapplication of the composition, simultaneously mixing the first andsecond components of the human body coating composition andspray-applying the human body coating composition onto a human body. 2.The process according to claim 1 wherein the mixing step is carried outby mixing the first and second components in a nozzle and immediatelythereafter discharging the self-tanning composition from the nozzle ontothe skin of a person.
 3. The process according to claim 1 wherein themixing step is carried out by simultaneously discharging the first andsecond components of the composition from separate nozzles onto the skinof a person so that the first and second components of the compositionare mixed on the skin of the person.
 4. A plural component self-tanningprocess comprising the steps of: providing a first component of aself-tanning composition which includes dihydroxyacetone; providing asecond component of the self-tanning composition including a tanenhancing agent which would destabilize the dihydroxyacetone of thefirst component if mixed herewith; maintaining the first and secondcomponents of the self-tanning composition separate from one anotherprior to application of the self-tanning composition to effectself-tanning; and simultaneously mixing the first and second componentsof the self-tanning composition and spray-applying the self-tanningcomposition onto a human body.
 5. The process according to claim 4wherein the mixing step is carried out by mixing the first and secondcomponents of the self-tanning composition in a nozzle and immediatelythereafter discharging the self-tanning composition from the nozzle ontothe skin of a person to be tanned.
 6. The process according to claim 4wherein the mixing step is carried out by simultaneously discharging thefirst and second components of the self-tanning composition fromseparate nozzles onto the skin of a person to be tanned so that thefirst and second components of the self-tanning composition are mixed onthe skin of the person to be tanned.